Metal roof



April 2, 1968 w. M. MURRAY METAL ROOF 3 Sheets-Sheet 1 Filed July 26, 1966 INVENTOR WAKEHELD M. MURRAY.

ATTORNEYS,

April 2, 1968 w. M. MURRAY METAL ROOF Filed July 26, 1966 5 Sheets-Sheet 2 If F no {I w n' i I I IL J in l L A i 14" I I i l I I i: l: I a

INVENTOR WAKEFIELD M. MURRAY.

ATTO RN 5Y5.

April 1968 w. M. MURRAY 3,375,622

METAL RQOF Filed July 26, 1966 5 Sheets-Sheet 3 INVENTOR. WAKEFIELD M. MURRAY.

MWMJ

ATTORNEYS.

United States Patent 3,375,622 METAL ROOF Wakefield M. Murray, Greensburg, Pa., assignor to Overly Manufacturing Company, Greensburg, Pa. Filed July 26, 1966, Ser. No. 568,053 6 Claims. (Cl. 52-90) The present invention relates to the pre-fabrication and subsequent assembly at the situs of slidably assembled interlocked roofing sheets providing a permanently water tight and wind resisting metal roofing for residences and other structures. Which roofing when installed permits expansion and contraction in all directions.

It is known in the art to provide a metal roof, for various types of structures, from prefabricated metal sheets which may be fastened together and to a roof deck or other supporting structures, in various manners. Such prior art roofs, where successful, required elaborate means for securing the prefabricated roof sheets together, to the deck or to other supporting structure and to prevent wind driven rain, snow or drainage from penetrating the joints between the sheets and to prevent displacement of the roof sheets during periods of high winds.

One object of the invention is to provide interlocking pre-fabricate roof sheets which may be economically and accurately fabricated and thereafter slidably assembled together at the situs so as to avoid exposed fastening means and to securely connect the pre-fabricated sheets to each other and to the roof deck. The term deck refers to any suitable supporting structure to which the said sheets are attached.

Another object of the invention is to interlock prefabricated roof sheets together and to a suitable drain channel to effect a tight roof preventing penetration by wind, driven rain or drainage.

These and other objects of the invention will be made apparent from the following detailed specification and the drawing forming a part thereof wherein:

FIG. 1 shows a partial plan view of the assembled roof sheets of the invention;

FIG. 2 shows an end elevation of the roof of FIG. 1;

FIG. 3 shows an enlarged partial cross-section of the roof taken on lines IIIIII of FIG. 1 illustrating the ridge and adjacent roof sheet constructions;

FIG. 3a shows an enlarged partial cross-section of a modified form of roof sheet shown in FIG. 3;

FIG. 3b shows an enlarged partial cross-section of a further modified form of roof sheet as shown in FIG. 3a;

FIG. 4 shows an enlarged cross-section of the roof taken on lines IV-IV of FIG. 1;

FIG. 5 shows a plan view of the roof sheet of FIG. 3;

FIG. 6 shows a side elevation of the roof sheet of FIG. 5; 7

FIG. 7 shows a plan view of the roof sheet of FIG. 3a;

FIG. 8 shows a side elevation of the roof sheet of FIG. 7;

FIG. 9 shows a plan view of one form of drain channel for connecting adjacent ends of the roof sheets;

FIG. 10 shows an enlarged exploded view of the assembly of adjacent roof sheets and drain channel of FIG. 3b.

Referring now to FIGS. 1, 2, and 3 of the drawing, the metal portion of the roof is comprised of interlocked main sheets 10, 10a, 10b, and 100 arranged in longitudinally extending rows interconnected at their adjacent side edges by suitable drain channels 16 and interconnected along their-longitudinal edges with the adjacent rows of sheets. Underlying the roof sheets 10, 10a, 10b, and 100 are suitable layers of roof felt, of suitable thickness, such as 30 lb. roof felt attached by any suitable means to the underlying roof deck 28.

Main roof sheets indicated generally at 10 in FIGS.

' In the case of roof sheet F these variations. As shown on 3,375,622 Patented Apr. 2, 1968 1, 2, 3 and 5 comprise an upwardly facing body portion 11 defined along one longitudinal edge by an upwardly overlapping flange 12 spaced from body portion 11 a sufficient distance to receive the inserted flange of a fastening clip 39 and a drain channel 16 as hereinafter described. Defining the opposite transverse edges, of the body portion 11, are depending flanges 13 terminating in inwardly turned bottom flanges 14 disposed in underlying spaced relation to the lower face of said sheet body portion 11. At the opposite or lower longitudinal edge of body portion 11 is a downwardly directed flange 15 which terminates in an inwardly turned flange portion 15a disposed in spaced relation to the sheet body portion 11.

The adjacent transverse edges of sheets 10 and 10a (FIG. 1) are connected in spaced relation by suitable drain channels, indicated generally as 16 (FIG. 9) which have a body portion 17 whose opposite sides are defined by upwardly overlapping flanges 18 disposed in spaced relation to said body portion 17 for reception of the roof sheet flanges 14. As shown in FIG. 9 of the drawing, the drain channel flanges 18, at opposite sides of body portion 17, terminate in spaced relation providing space for longitudinal expansion of the roof sheets 10 engaged therewith. Adjacent one end of the drain channel, the body portion 17 has an overlying inturned flange 19, notched intermediate its ends, as at 20, for engagement by an anchoring clip, indicated generally as 21, having a body portion 22 off-set at 23. At opposite ends of clip bodp portion 22 are flanges 24 and 25, for respectively engaging the drain channel flange 19 and attachment to the roof deck. Adjacent the opposite end of drain channel 16, the body portion 17 may be provided with an underlying flange 26, which may be in substantial spaced relation as shown, or merely an inturned flange for engaging an underlying member.

Referring now to FIGS. 1 and 4 of the drawing, FIG. 4 represents a typical cross-section taken on lines IV-IV of FIG. 1 illustrating the wood supports between the drain channels and the roof deck, the roof sheet supports and the rake trim. As shown in FIG. 1, it is typical that roof sheets 10 may not be uniform in length over the entire roof surface, and in fact may vary in both length and width from installation to installation. FIG. 4 shown in cross-section the modifications necessary to accommodate the left side of FIG. 4, roof sheets 10 and 10a, at their adjacent ends, are connected by drain channel 16 and underlying the drain channel is a drain channel support 27 of suitable material, including wood. The support 27 is in turn supported upon the underlying roof felt and the wood deck 28. As shown, the drain channel 16 of FIG. 9, secures together the adjacent edge flanges 14 of roof sheets 10 and 10a in spaced relation such as about one-eighth inch, more or less, to permit expansion and contraction movement of the sheets 10 and 10a. It will be noted at FIGS. 3 and 4 that both the drain channels and the roof sheets are preferably not secured in fixed relation to the wood deck, but are retained in assembled relation therewith by suitable clip members such as 21, which in turn are attached to support 27 or deck 28. Thus the roof sheets and drain channels being slidably connected by the several flanges thereof permit relative movement therebetween under temperature changes, but by reason of the interlocking flanges and the clips are held against displacement the wood deck 28. It will be understood supports 27 are suitably attached throughout their length to Wood deck 28. I

At the right side of FIG. 4 of greater thickness than support 27, thus compensating for omission of the drain channel, and maintaining roof sheet 10a in the general horizontal plane of roof sheet 10;

10a one longitudinal end porrelative to 5 the roof sheet support 29 is tion will be provided with a flange 14, as at FIG. 4, and the opposite longitudinal end portion may be in abutting or have an overlapping flange engagement with rake trim sheet 30, which latter sheet 30 is retained in place by suitable clip members 31 spaced longitudinally of rake sheet 30. One leg of clip 31 may be secured to a suitable support, such as the roof deck 28, by any suitable means such as headed screw or nail. The opposite leg of clip 31 may be suitable attached to the adjacent face of the rake sheet 30, as by flange 30a.

It will be noted, upon reference to FIGS. 3 and 5, that the drain channel support members 27 and roof sheet support members 29 beneath roof sheets and 10a are tapered, in thickness, to conform to the slope of the roof sheets 10 and 10a. However, the eave sheets 10b, 10c and the drain channels 16 associated therewith are supported directly upon the roof deck 28 and overlying roof felt and therefore do not require support members such as 27 and 29.

Referring now to the lower left hand end of FIG. 3, the upper surface of roof wood deck 28 has mounted thereon a layer 32 of roof felt, such as lb. roof felt, which is secured in any suitable manner to the underlying roof deck. Secured to the lower end of the eave of the roof are metal starter sheets, indicated generally at 33, of several inches or more in width and spaced several feet or more on centers. Sheet 33, comprises a body portion 34 extending beyond deck 28 and provided with an inturned flange 35 terminating in a flange 36 depending below same. The lower end of portion 36, is preferably terminated in a suitable stiffening flange 37. The inner end of sheet 33, body portion 34, terminates in a suitable overlapping flange 38 which is attached to the wood deck 28 by a suitable clip 39 and a fastener, such as the nail 40.

As further shown in FIGS. 1 and 3, the roof sheets 10b and 10c forming the eave of the roof are laid directly upon the starter sheets 33 and are connected by the usual drain channels 16 (FIG. 9), except that flange 26 thereof is omitted and rectangular tabs X are provided to nail the channel 16 to the roof deck. The roof sheets 10b and 10c at the eaves are provided with an inturned bottom flange 40 which overlaps starter sheet flange 35 FIG. 3. The sides of sheets 100 at the rake will abut or be otherwise attached to the rake trim 30 as shown in FIG. 4 Roof sheets 10b and 100 will attach to the drain channel in the same manner as do sheets 10 and 10a.

As best shown in FIGS. 2 and 4 one longitudinal end the roof sheets at the rake ends of the roof are closed to exclude rain, snow and wind. The preferred method of so doing is to provide a suitable flange, such as 30, upon a side of the outer face of the roof sheets to extend downwardly over the exposed roof deck, with the lower edge of theflange provided with an inturned portion to receive a suitable clip 31 attached the roof deck 28. Such clip can be continuous, but suitably may be of three to six inches in length spaced 12 to 18" on centers. The ridge cap 6 formed as in cross-section as shown in FIG. 3 will also be closed at its longitudinal ends to exclude weather. The ridge cap comprises two half-sections 41 and 42 which meet together as shown. At opposite ends of the roof, each ridge cap section 41 and 42 will be provided with a closure flange as are the roof sheets as in FIG. 4. The lower edge of the said flange may be suitably attached to the roof deck 28 and or rake trim 30.

Referring now to the several forms of roof sheets indicated in FIGS. 3, 3A and 3B, the roof sheets of FIG. 3 are shown in detail in FIG. 5. The roof sheets of FIG. 3a are shown in detail in FIG. 7, wherein the body portion 11a and flanges 14a and 15a are similar to those of FIG. 5. The flange 12a is spaced a greater distance above the body portion 11a and is connected at one end to body 11a by flange 12b and at the opposite end has a depending flange 120. The flange 15a of FIG. 7 is similar to flange 15 of FIG. 5. The roof sheets of FIG. 3B are substantially identical with that shown in FIG. 7 of the drawing,

except that the body portion 11a and flanges 12a and 15a thereof are at right angles toeach other as shown in FIG. 10. With this type of construction the roof deck increases in thickness as each roof sheet is added, so that the roof deck as shown in FIG. 3B is thicker at the ridge, than at the eaves.

As shown in FIGS. 9 and 10 the drain channels, indicated generally therein as 16 and 16a, are modified to accommodate the several forms of roof sheets. The drain channel 16, of FIG. 9, is employed with roof sheets 10 of FIG. 5 and the roof sheet 10D of FIG. .7. Drain channel 16a is employed with the roof sheets 10E of FIG. 3B of the drawings. An exploded view of the assembly of drain channel 16a and sheets 10E are shown in FIG. 10 of the drawing.

Referring now to FIGS. 3, 4 and 9 of the drawing, the drain channel 16, not shown in FIG. 3, is supported upon member 27 as shown in FIG. 4. The member 27 is attached by any suitable means to roof deck 28 which is of uniform thickness from eave to ridge. Flange 26 of drain channel 16 may be engaged between the adjacent end of member 27 and roof deck 28. The opposite end of the drain channel 16 is attached by clip 21 to member 28 by any suitable means, such as a nail. Clip portion 25 may be raised, for this purpose, the nail entered through the body of the clip and thereafter portion 25 bent downwardly over the nail head. In such cases where the roof sheets 10 are of excessive width, the drain channel 16, may be provided with side clips (x) for attachment to the member 27, which will be of suitable width. The flanges 14 of adjacent roof sheets 10 may then be engaged between drain channel flanges 18 and drain channel body 17, as shown in FIG. 4. Thereafter the roof sheet flange 12 may be attached to the roof deck 28 by a suitable clip 39, as shown in FIG. 3. It will be observed, in FIG. 3, that the roof section was taken to one side of the drain channel '16, to better illustrate attachment of the ends of the sheets with each other. The roof sheet 10, highest up the slope of the roof, has its flange 12 overlapped by roof cap member 41 and its flange 15,. lower down on the roof slope, engaged by flange 12a of the adjacent roof sheet. At the eave of the roof of FIG. 3, the spacing of starter sheet 33 and roof sheet 101) is exaggerated to better show the details of construction.

Referring now to FIGS. 3A, 7 and 8 of the drawing, roof sheet 10D is also supported by wedge shaped members 27 as is sheet 10. The drain channel employed with these sheets is a modified form of those shown in FIGS. 9 and 10. That is, the drain channel (not shown) has a body portion and top flange as shOWn in FIG. 10, but a bottom flange as shown in FIG. 9. The drain channel body portion, however, is sloped to conform to the roof sheet body portion 11a of FIG. 7. With such an arrangement (FIG. 3A), roof sheet -11a has its flange 12a overlapped by drain channel flange 19a (FIG. 10) and the flange 15a of sheet 10D overlaps and nests beneath flange 12a of the next roof sheet lower down the roof slope. The side flanges 14a of roof sheets 10D engage beneath the flanges 18 of the drain channel of FIGS. 9 and 10. Preferably the drain channel employed with roof sheets 10D has side lugs X (FIG. 9) for attachment to the roof deck 28 or wedge sloped members 27. The eave sheet 101;, as

shown has a top longitudinal flange 12a and a bottom flange, same as eave sheet 10b.

Referring now to FIGS. 4 and 10, the exploded view in FIG. 10 shows roof sheets 10E (of FIG. 3B) in spaced relation to the drain channel 16a and FIG. 4 shows the flanges of adjacent sheets 11 and 11a engaged with the flanges 18 of the drain channel. The joints between adjacent sheets, as shown in FIG. 1, are spaced so that water drainage from one drain channel discharges upon the mid-portion of the adjacent roof sheet measuring down the roof slope. When assembling the roof sheets upon the roof deck, as hereinbefore discussed, the sheets are laid from the bottom of the roof slope transversely of the roof and upwardly to the ridge of the roof.

As shown in FIG. 10, the roof sheet E at the bottom of the view represents a lower row of roof sheets -10E each of whose end edges are connected by drain channels 16a as hereinafter discussed, with opposite ends of the said row provided with a rake sheet sealing the ends of the row as hereinbefore discussed. The flange 12a of each sheet 10E has a suitable notch 12x for engagement by the flange 41 of drain channel 16a to retain sheet 10E flange portion 12 in abutment with the adjacent wall of stepped roof deck 28. Drain channel 16a is retained in position by suitable fasteners, such as nails driven through lugs, the underlying roof felt and the deck 28. At the upper end of drain channel 16a, flange 19a is engaged by a suitable clip 21a which in turn is attached to the adjacent face of roof deck 28. Flanges 14a of roof sheets 1013 are engaged with flanges 18a, in a manner similar to that shown in FIG. 4, and sheets 10E are moved upwardly until flanges 12a thereof move beneath flange 19a, of drain channel 16a and into abutment with drain channel flange portion 19b. Preferably flange 12c of sheet 10E has a suitable notch therein engaged by a suitable clip Z which may be nailed to roof deck 28. Roof sheets 10E, adjacent the top of FIG. 10 would then be applied over the lower row of roof sheets 10E joined by drain channels 16a to provide succeding rows of roof sheets extending upwardly of the roof. It will be understood that the ridge cap 41 would be applied to the upper flanges 12a of roof sheets 10E in a manner similar to that shown in FIG. 3A.

From the foregoing it will be apparent that the three forms of roof sheets shown in FIGS. 3, 3A and 3B have common features, such as an upwardly facing body por tion, side flanges for interlocking engagement with the drain channel side flanges and longitudinal flanges of the 7 sheets disposed upslope and downslope therefrom. Each roof sheet, except the eave sheets 10b and 10c, is independently connected to the roof deck, on the upslope edge by at least one slip, each roof sheet longitudinal edge portion is held in place upon the roof deck, or sheet support strip 27, by the drain channel and overlapping flanges of the adjacent roof sheets upslope and downslope therefrom. It will be obvious, to those skilled in the art, that modifications may be made in the details of construction without departing from the invention as defined in the appended claims.

I claim:

1. In a metal roof for assembly upon and attachment to a suitable roof deck comprising prefabricated sheets arranged in rows transversely of the roof and in overlapping rows longitudinally of the roof slope, in combination:

(a) spaced sheet means of rectangular shape having oppositely directed longitudinal extending flanges and opposing spaced flanges defining the transverse edges of said sheet means,

(b) clip means engaging the upslope longitudinal flange of each sheet and attached to the adjacent roof deck in spaced relation to said flange.

(c) drain channel means secured to said roof deck between said spaced sheet means and engaging the adjacent sheet means transverse flanges to retain said sheet means in transverse and vertical fixed relation to said deck.

(d) clip means engaging and retaining said drain channel in vertical fixed relation to said roof deck.

(e) each said sheet means bottom longitudinal flange embracing the underlying sheet means longitudinal flange to retain the two adjacent sheet means against vertical separation.

2. The metal roof as defined in claim 1, wherein each row of roof sheet transversely of the slope have their drain channel connection disposed intermediate the ends of the upslope sheets.

3. The metal roof as defined in 1, wherein each roof sheet, intermediate the eave and ridge sheets is independently retained in fixed relation to the roof deck by means of a clip member and in addition is interlocked about its periphery in overlapping engagement with adjacent sheets and drain channels providing for expansion and contraction in the plane of the roof deck but fixed against vertical displacement relative to the roof deck.

4. The metal roof, as defined in claim 1, wherein each row of roof sheets is retained in leakproof assembly by interlocking underlying drain channels maintaining the sheets in a row in spaced relation providing for expansion and contraction of the sheets and channels relative to each other and to the adjacent rows of sheets.

5. The metal roof as defined in claim 1, wherein each roof sheet in each row of sheets is slidably engaged with an underlying drain channel and overlapped upon its upslope and downslope edges by adjacent roof sheet flanges providing a barrier to penetration of wind and weather.

6. In a metal roof comprising prefabricated sheets arranged in rows in end to end relation and in successive rows, comprising:

(a) a plurality of substantially rectangular sheets pro vided with re-entrant underlying flanges at opposite end edges thereof;

(b) one longitudinal edge of each said sheets having an overlying flange disposed in vertical spaced relation to the body of said sheet for substantially the length thereof;

(c) the opposite longitudinal edge of each said sheets having a depending flange for substantially the length thereof and which terminates in an inturned flange disposed in greater spaced relation to the body of the sheet than the said overlying flange;

(d) means connecting adjacent end edges of the rectangular sheets and comprising a body portion of less width than the longitudinal length of the said rectangular sheets and of a length preferably less than the width of said rectangular sheets, flanges along the length of each side edge of said body portion overlying same and terminating in a spaced relation greater than twice the thickness of said rectangular sheets, a flange on one end of said body portion depending below the plane thereof and a reentrant flange at the opposite end of said body portion disposed in overlying spaced relation to said body portion and clip means engaged with said overlying means and extending therefrom for attachment to the underlying roof supporting structure to maintain said connected rectangular sheets in fixed relations to the said roof supporting structure.

References Cited UNITED STATES PATENTS FOREIGN PATENTS 1,330,174 5/1963 France.

HENRY C. SUTHERLAND, Primary Examiner. FRANK ABBOTT, Examiner.

C. W. ISAACS, Assistant Examiner. 

1. IN A METAL ROOF FOR ASSEMBLY UPON AND ATTACHMENT TO A SUITABLE ROOF DECK COMPRISING PREFABRICATED SHEETS ARRANGED IN ROWS TRANSVERSELY OF THE ROOF AND IN OVERLAPPING ROWS LONGITUDINALLY OF THE ROOF SLOPE, IN COMBINATION: (A) SPACED SHEET MEANS OF RECTANGULAR SHAPE HAVING OPPOSITELY DIRECTED LONGITUDINAL EXTENDING FLANGES AND OPPOSING SPACED FLANGES DEFINING THE TRANSVERSE EDGES OF SAID SHEET MEANS, (B) CLIP MEANS ENGAGING THE UPSLOPE LONGITUDINAL FLANGE OF EACH SHEET AND ATTACHED TO THE ADJACENT ROOF DECK IN SPACED RELATION TO SAID FLANGE.. 